Integrated wall system

ABSTRACT

A composite wall system includes a foundationless wall substructure such as a sheet piling wall with a base portion embedded in the ground and an exposed portion extending above the ground, and one or more fascia panels or sheets such as synthetic simulated stonework panels applied over the foundationless wall substructure. Components of the wall system prevent debris from entering between the wall substructure and the fascia panels, and in seawall applications prevent water incursion and resist wave action.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 61/024,395 filed in the United States Patent and Trademark Office on Jan. 29, 2008, which is hereby incorporated herein by reference in its entirety for all purposes.

TECHNICAL FIELD

The present invention relates generally to the field of structural building elements, and more particularly to a composite wall structure, methods of construction and use thereof, and components for use therein.

BACKGROUND OF THE INVENTION

Various wall structures are utilized in the building and construction trade. For example, retaining walls are often constructed to resist lateral pressure and prevent movement of earth behind the wall. Seawalls and dikes may be constructed to prevent erosion of a shoreline, to break the force of waves, and/or for aesthetic purposes. Barrier walls are used to restrict ingress and egress, to mark boundaries, for security, and for various other functional or decorative purposes. Traditionally, such wall structures have been constructed of masonry materials including brick, stone, block, and concrete, of wooden cross-tie members, and/or of steel or other structural materials.

In many seawall and retaining wall applications, the soil is not conducive to building with heavy stones or bricks. To build a wall from these materials requires substantial excavation and a foundational footing in order to support the vertical load. This is expensive and time consuming in general, and in those applications involving proximity to water, such as a seawall, it is generally cost prohibitive. The soils underlying such applications are typically very soft because of their water saturation. Softer soils generally require a deeper and wider foundation which can increase the cost exponentially. Furthermore, excavating and pouring foundations underwater is an expensive and time-consuming process. For these reasons, seawalls and retaining walls in the vicinity of water are rarely constructed of stone, brick or other masonry materials.

In the case of retaining walls not in the vicinity of water, and which are typically supported by harder soils, decorative materials such as stone or brick are often applied only as an aesthetic facing on the wall, and are supported by a heavy concrete sub-wall structure and foundation. Alternatively, simulated stone molded panels, for example as shown in U.S. Pat. No. 6,726,864, may be applied over a wall substructure of concrete or other structural material(s). This manner of construction generally involves significant labor and material expenses. Such walls typically require a separate and substantial underlying foundation, commonly of steel-reinforced poured concrete construction, as well as a high degree of soil stability and compaction beneath and around the wall structure to anchor and support the wall's weight.

Another alternative sometimes used to build retaining walls is the geogrid and block construction system, wherein the geogrid reinforces and stabilizes soil behind the wall. This technique reduces the load on the face of the wall and allows for alternative decorative surfaces and textures to be used. This construction technique typically requires a foundation and it can be quite costly to install the geogrid and blocks.

Further improvements have been made in the field of wall structure construction. For example, sheet-piling walls and methods of construction thereof, as shown for example in U.S. Pat. No. 7,059,807, U.S. Pat. No. 7,056,066, U.S. Pat. No. 7,025,539, U.S. Pat. No. 6,575,667, U.S. Pat. No. 6,053,666, U.S. Pat. No. 6,033,155 and U.S. Pat. No. 6,000,883, have been developed. These types of wall systems typically do not require a separate foundation, as they are not nearly as heavy as walls of masonry or most other more traditional materials of construction, and as they derive considerable lateral support and stability from being partially embedded into the ground. As a result, sheet-piling wall systems are frequently utilized in seawall construction and other applications in wet or otherwise unstable soils, and are generally less expensive to construct as compared with walls of masonry and many other traditional materials of construction.

Sheet-piling wall systems typically include a number of interconnected elongate vertically-driven pile members, which results in the walls having a corrugated or horizontally segmented appearance. Consumers in the marketplace have come to accept this somewhat utilitarian appearance as a necessary characteristic of the wall's manner of construction. Moreover, the application of any sort of decorative facing to a sheet-piling; seawall system would heretofore have been considered counterintuitive to those of skill in the art, as the corrugations or seams of a standard sheet-piling wall could permit water and debris to collect in the spaces behind the facing and could permit wave action to cause detachment of the facing material.

SUMMARY OF THE INVENTION

In example embodiments, the present invention provides improved wall systems and components therefor, and further provides improved methods of constructing wall systems. Wall systems, components and construction methods according to the present invention are adaptable for use in various applications, including for example, seawalls, dikes, piers, retaining walls, barrier walls, and the like.

In one aspect, the present invention is a composite wall system that includes a foundationless wall substructure having a base portion embedded in the ground, and an exposed portion not embedded in the ground. The composite wall system further includes a panelized fascia attached to the foundationless wall substructure over at least the exposed portion thereof.

Optionally, the foundationless wall substructure takes the form of a sheet piling wall, a driven or jetted-in-place concrete wall, vinyl pilings, fiberglass reinforced plastic (FRP) pilings, steel pilings, wood, and/or other form of wall substructure component(s) not requiring a separately formed foundation. The fascia optionally takes the form of a synthetic molded panel having a simulated stone work, simulated brick work, or other aesthetically appealing outer surface.

In another aspect, the invention is a composite wall system including a sheet-piling substructure incorporating a plurality of elongate pile members, each pile member having at least one engagement member for connection with an adjacent pile member. The composite wall system also includes a fascia panel for application over at least a portion of the sheet-piling substructure. The fascia panel has an inner face for attachment to the sheet-piling substructure, and a decorative outer face.

In still another aspect, the invention is a cap member for a composite wall system, the cap member including an upper panel and a front panel, the upper panel and the front panel each having an inner portion for engagement with a substructure, and an outer portion including a decorative surface.

In another aspect, the invention is a method of fabricating a composite wall system. The method of the invention includes driving at least one substructure member partially into the ground, whereby the substructure member defines an embedded portion within the ground and an exposed portion above the ground. The method of the invention further includes applying a panelized fascia over at least the exposed portion of the at least one substructure member.

In yet another aspect, the invention is a method of designing and/or fabricating a composite wall system. The method of the invention includes providing at least one substructure member having an outer attachment surface, and providing at least two types of fascia panel. A first of the at least two types of fascia panel has a first decorative appearance, and a second of the at least two types of fascia panel has a second decorative appearance different from the first decorative appearance. The method of the invention further includes selecting one of the at least two types of fascia panel for attachment to the outer attachment surface of the substructure member.

These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of the invention are exemplary and explanatory of preferred embodiments of the invention, and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, in partial cutaway, showing a composite retaining wall system according to an example embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a composite seawall system according to another example embodiment of the present invention.

FIG. 3 is a cross-sectional view showing a composite pier wall and walkway system according to an example embodiment of the present invention.

FIGS. 4 and 5 show sectional views of composite wall systems and wall cap components according to example embodiments of the present invention.

FIG. 6 is a cross-sectional view of a composite wall system according to another example embodiment of the present invention.

FIG. 7 is a front view showing the exposed face of a composite wall system according to another example embodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention may be understood more readily by reference to the following detailed description of the invention taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.

Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.

With reference now to the drawing figures. Wherein like reference numbers represent corresponding parts throughout the several views. FIG. 1 shows a section of a retaining wall system 10 according to an example form of the invention. The wall system 10 comprises a foundationless substructure in the form of a sheet piling wall wherein a plurality of interconnected elongate pile members 12 are driven into the ground 14, such that they define a base portion embedded in the ground and an exposed portion not embedded in the ground. In the depicted embodiment, the elongate pile members 12 comprise plastic sheet pile members formed of polyvinyl chloride, polypropylene, polyethylene and/or other suitable synthetic or polymeric material(s). In alternate forms, the foundationless substructure comprises pile members or panels formed of steel, aluminum or other metal(s), concrete, wood, fiber-reinforced plastic (FRP), and/or various other substantially rigid construction material(s).

In the depicted embodiment, each elongate pile member 12 includes a male connection member or flange along its first lateral side, and a female connection member or channel along its second lateral side, for inter-engaging connection with cooperative connection members of adjacent elongate pile members, to provide the wall with improved structural integrity. In example forms, the elongate pile members 12 comprise a generally planar front face, whereby the interconnected pile members form a sheet piling wall having a substantially continuous and smooth outer surface 16. In alternate forms, the pile members define an angulated channel cross-sectional configuration, forming a corrugated wall surface. One or more anchor bars 20 optionally extend through the elongate pile members for engagement with one or more layers of geogrid sheet(s) through which the anchor bars are interlaced, to reinforce and anchor the wall substructure.

The retaining wall 10 further comprises at least one panelized fascia 30 attached to the outer surface 16 of at least the exposed portion of the wall substructure. In example forms, the fascia panel 30 is a sheet-like or strip-like synthetic molding or extrusion formed of polymeric, ceramic, masonry, and/or composite material(s), and having a simulated stone, brick, or other aesthetically appealing outer surface contour and texture. In example forms, the outer face of each fascia panel 30 presents the appearance of a plurality of individual stones, bricks, or other separate building component units. The fascia panel(s) 30 is/are affixed to the underlying wall substructure in a permanent or semi-permanent manner, such as for example by adhesive, connection strips, screws, clips, integrally formed engagement members, and/or other fasteners or attachment means. In larger applications, a plurality of fascia panel elements 30 are applied to the underlying wall substructure in an array of interlaced or adjacently arranged elements. Optionally, one or more natural or synthetic bumpers or wale members 40 is/are affixed to the wall substructure, to the fascia panel 30, or are integrally formed as part of the fascia panel. A starter strip, flashing, or other sealing means is/are optionally provided at the upper and/or lower edges of fascia panel element(s) 30, and/or at interfaces between the fascia panel element(s) and other components such as bumpers or wales, to prevent debris and/or wave action from entering between the fascia panel element(s) and the underlying wall substructure. Additionally or alternatively, the inner faces of the fascia panel element(s) 30 and/or the sealing means have surface profiles contoured to match the corrugations or channels of the underlying wall substructure to prevent debris and/or wave action from entering therebetween.

The retaining wall 10 optionally further comprises a cap member 50 overlying and affixed onto the upper end of the wall substructure 12 and/or the fascia panel 30. In example forms, the cap member 50 comprises a generally C-shaped or U-shaped molding or extrusion optionally including a metal or plastic inner reinforcing flange 52 and having a concrete or composite outer cladding 54 providing a simulated stone or masonry surface appearance. The cap member 50 can be affixed to the underlying wall elements, such as for example by adhesive or fasteners, or alternatively can comprise an internal configuration that mates with cooperatively shaped components of the underlying wall elements to secure the cap member in place. Optionally, the cap member 50 functions as a connection member, engaging portions of the wall substructure 12 and the fascia panel 30 to connect the two together, and/or to prevent debris or water from entering therebetween.

FIG. 2 shows a section of a seawall system 110 according to another embodiment of the present invention. The seawall system 110 comprises a wall substructure 112, one or more fascia panels 130 a , 130 b , and a bumper or wale 140, in similar fashion to those corresponding elements of the above described embodiment. Optionally, a tie rod 144 anchors the wall system 110 into the ground or to an adjacent anchoring body (unshown). An upper cap member 150 comprises a back panel 152, a top panel 154, a front panel 156 and a lower lip 158, to define a generally C-shaped molding or extrusion of concrete or composite material presenting a decorative outer surface texture and appearance. Optionally, the wall substructure includes a top sill plate 160 and/or an attachment rail 162, formed for example of pressure treated lumber or composite material, onto which the cap member 150 is affixed.

FIG. 3 shows a cross-sectional detail of a pierwall system 210 according to another embodiment of the present invention. The wall system 210 comprises a wall substructure 212 and one or more fascia panels 230 a , 230 b , in similar fashion to those corresponding elements of the above described embodiments. The wall system 210 includes front and back top sill plates 260 a , 260 b and front and back rails 262 a , 262 b , formed for example of pressure treated lumber or composite material. A cap member 250 formed of concrete or composite material provides a walking surface along the top of the pier wall system 210.

FIG. 4 shows a cross-sectional detail of a wall system 310 according to another embodiment of the present invention. The wall system 310 comprises a wall substructure 312, one or more fascia panels 330, and a cap member 350 in similar fashion to those corresponding elements of the above described embodiments. FIG. 5 shows a similar wall system 410 having a wall substructure 412, and an integrally formed cap member and fascia panel 470.

FIG. 6 shows a seawall or retaining wall 510 according to another embodiment of the invention. A foundationless wall substructure 512 is formed from one or more sheet piling members, concrete panels, or other structural elements, and one or more fascia panels are attached thereon (in the depicted embodiment, upper and lower arrays of fascia panels 530 a , 530 b are applied onto the wall substructure). An upper wale 540 a and/or a lower (or dropped) wale 540 b are optionally also provided, extending transversely and generally horizontally along at least a portion of the wall's length. One or more tie rods 544 a , 544 b are optionally installed through the wall substructure 512, the wales 540, the cap 550, and/or other wall component(s), to anchor and brace the wall system into adjacent ground substrate or structure. In the depicted embodiment, the cap 550 of the wall takes the form of a flat slab or block extending transversely and generally horizontally over the upper end of at least a portion of the wall's length. The cap 550 can be formed of natural stone, concrete, wood, and/or synthetic material(s). Optionally, a wale fascia strip 575 is applied to cover underlying wall elements or material transitions, for decorative purposes and/or for resisting intrusion of debris and wave action.

FIG. 7 shows a wall 610 according to another embodiment of the invention. The underlying wall substructure comprises a plurality of sheet piling members 616, each defining a retaining slot 615, and optionally having a series of vertically spaced receiver openings 617 therein. A starter strip 625 is affixed to the sheet piling members 616 at about (or just below) the mean low water level for seawall applications, and at about (or just below) the soil level for retaining wall applications. A plurality of fascia panel elements or modules 630 are affixed to the sheet piling members 616 above the starter strip 625. Each of the fascia panel modules 630 has a generally S-shaped or Z-shaped profile comprising an upper rectangular portion and a lower rectangular portion, the upper and lower rectangular portions being partially horizontally offset from one another and joined at a medial portion, such that adjacent fascia panel modules interlock or combine to form a substantially continuous surface. Each fascia panel module can include an outer face molded to present the appearance of one or more stones, bricks, blocks or other building components, and fascia panel modules having two or more complementary patterns can be provided to present a more continuous or evenly distributed visual appearance (i.e., to break up or disguise the repeating pattern of the fascia modules). The starter strip may include sealing means for preventing debris and/or water from entering between the sheet piling members and the fascia panel modules, can provide a horizontal reference line for alignment of the first course of fascia panel modules during installation, and/or can provide attachment between the fascia panel modules and the sheet piling members. A cap member 650 is optionally provided along the upper ends of the sheet piling members 616. The fascia panel modules 630, and optionally also the starter strip 625, are affixed to the sheet piling members 616 by mounting lugs 635 projecting from the back faces of the fascia panel modules. The lugs 635 are engaged and retained in the retaining slot 615 by means of interengaging male and female profiles. In alternate forms, the lug-and-slot coupling system is reversed, with the lugs comprising projections from the sheet piling members or other wall substructure, and the slots being formed in the fascia panel(s). In assembling the wall 610, the sheet piling members 616 are driven into the ground in typical fashion. The starter strip 625 is installed onto the sheet piling members at the desired level, for example at a true horizontal. The fascia panel modules 630 are attached by inserting the lugs 635 into the slots 615, as by sliding the fascia panel modules down from the top of the sheet piling members, or by insertion of the lugs into receiver openings 617 (if provided) near the desired point of attachment and sliding them up or down in the slots for final placement. Additional attachment may optionally be provided between the fascia panel modules and the sheet piling members, for example by means of adhesive, screws or other fasteners, clips, integral snap couplings, or the like. The cap member 650 may be engaged by one or more couplings or other attachment means, to prevent upward movement and possible detachment of the fascia panel modules.

In its various example embodiments, the composite wall system of the present invention may be fabricated by driving one or more substructure members partially into the ground. In example forms, the substructure members take the form of sheet piling members or wall panel components. An embedded portion of the wall substructure serves to anchor the wall in the ground and resist lateral forces. An exposed portion of the wall substructure extends a distance above the ground. Anchor bars and/or tie rods may be installed to reinforce the wall substructure. One or more panelized fascia members are then applied over at least the exposed portion of the wall substructure. In example forms, the panelized fascia members take the form of sheet-like or strip-like synthetic moldings or extrusions formed of polymeric, ceramic, masonry, and/or composite material(s), and having a simulated stone, brick, or other aesthetically appealing outer surface contour and texture. The fascia members can be affixed to the underlying wall substructure by adhesive, connection strips, screws, clips, integrally formed engagement members, and/or other permanent or semi-permanent fasteners or attachment means. Optionally, one or more bumpers or wale members are affixed to the wall substructure, to the fascia panel, or are integrally formed as part of the fascia panel. A cap member is optionally installed over the top of the wall substructure and panelized fascia members, and in example embodiments serves as an attachment mechanism to join the substructure and fascia and/or serves to prevent water or debris from entering therebetween.

The invention also includes methods of designing and fabricating composite wall systems, wherein multiple different types of fascia panels are provided for attachment to an outer attachment surface of underlying substructure members. For example, a first type of fascia panel can comprise an outer surface having a first decorative appearance in the form of simulated stonework, and a second type of fascia panel can comprise an outer surface having a second decorative appearance in the form of simulated brickwork. Alternatively, the first and second decorative appearances can be stonework or brickwork of differing colors, differing tones, differing geometric configurations or sizes, differing textures, or various other differing decorative appearances. The first and second types of fascia panels, however, will both be compatible for attachment to the common shared form of underlying wall substructure elements. A designer will then specify or select one or more of the multiple different types of fascia panels for attachment to the wall substructure. The design and fabrication methods according to the present invention can optionally further comprise the provision of different types of cap members, each type having a differing outer surface appearance; the provision of different types of bumper or wale members, each type having a differing outer surface appearance; and/or the provision of different types of other wall system components, each type having a differing outer surface appearance, whereby the designer specifies or select one or more of the different types of wall system components for attachment to the wall substructure.

While the invention has been described with reference to preferred and example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims. 

1. A composite wall system comprising; a foundationless wall substructure having a base portion embedded in the ground and an exposed portion not embedded in the ground; and a panelized fascia attached to the foundationless wall substructure over at least the exposed portion thereof.
 2. The composite wall system of claim 1, wherein the foundationless wall substructure comprises a sheet piling wall.
 3. The composite wall system of claim 2, wherein the sheet piling Wall comprises a plurality of vinyl pile members.
 4. The composite wall system of claim 2, wherein the sheet piling wall has a substantially continuous outer surface.
 5. The composite wall system of claim 2, wherein the sheet piling wall comprises metal pile members.
 6. The composite wall system of claim 1, wherein the foundationless wall substructure comprises at least one concrete wall panel.
 7. The composite wall system of claim 1, wherein the panelized fascia comprises a simulated stonework outer surface.
 8. The composite wall system of claim 1, wherein the panelized fascia comprises a simulated brickwork outer surface.
 9. The composite wall system of claim 1, wherein the panelized fascia is applied only to the exposed portion of the foundationless wall substructure.
 10. The composite wall system of claim 1, further comprising a cap member for attachment over upper edges of the exposed portion of the foundationless wall substructure and the panelized fascia.
 11. The composite wall system of claim 10, wherein the cap member comprises a simulated stonework outer surface.
 12. The composite wall system of claim 10, wherein the cap member comprises a simulated brickwork outer surface.
 13. The composite wall system of claim 1, further comprising a lug-and-slot coupling system for attaching the panelized fascia to the foundationless wall substructure.
 14. The composite wall system of claim 1, further comprising a starter strip affixed to the foundationless wall substructure beneath the panelized fascia.
 15. The composite wall system of claim 1, wherein the panelized fascia comprises a plurality of fascia modules, each fascia module comprising an upper portion and a lower portion, the upper and lower portions being partially horizontally offset from one another and joined at a medial portion, such that adjacent fascia panel modules combine to form a substantially continuous surface.
 16. A composite wall system comprising: a sheet-piling substructure comprising a plurality of elongate pile members, each pile member having at least one engagement member for connection with an adjacent pile member; and a fascia panel for application over at least a portion of the sheet-piling substructure, the fascia panel having an inner face for attachment to the sheet-piling substructure, and a decorative outer face.
 17. The composite wall system of claim 16, wherein the elongate pile members comprise a synthetic polymer material.
 18. The composite wall system of claim 16, wherein the elongate pile members comprise metal.
 19. The composite wall system of claim 16, wherein the elongate pile members define a substantially continuous attachment surface for attachment of the inner face of the fascia panel thereto.
 20. The composite wall system of claim 16, wherein the fascia panel comprises a synthetic molding.
 21. The composite wall system of claim 16, further comprising a cap member for engagement over a top portion of the sheet-piling substructure and the fascia panel, the cap member having a decorative outer face.
 22. The composite wall system of claim 16, further comprising a lug-and-slot coupling system for attaching the fascia panel to the sheet-piling substructure.
 23. The composite wall system of claim 16, further comprising a starter strip for attachment to the sheet-piling substructure below the fascia panel.
 24. The composite wall system of claim 16, wherein the fascia panel comprises a plurality of modules, each module comprising an upper portion and a lower portion, the upper and lower portions being partially horizontally offset from one another and joined at a medial portion, such that adjacent modules combine to form a substantially continuous surface.
 25. A cap member for a composite wall system, said cap member comprising an upper panel and a front panel, the upper panel and the front panel each having an inner portion for engagement with a substructure, and an outer portion comprising a decorative surface.
 26. The cap member of claim 25, further comprising a back panel, wherein the front panel, the upper panel and the back panel combine to form a generally U-shaped profile.
 27. The cap member of claim 25, being at least partially formed of concrete.
 28. The cap member of claim 25 further comprising a reinforcing flange within the concrete.
 29. A method of fabricating a composite wall system, said method comprising: driving at least one substructure member partially into the ground, whereby the substructure member comprises an embedded portion within the ground and an exposed portion above the ground; and applying a panelized fascia over at least the exposed portion of the at least one substructure member.
 30. The method of claim 29, wherein the at least one substructure member comprises a sheet piling wall.
 31. A method of fabricating a composite wall system, said method comprising: providing at least one substructure member having an outer attachment surface; providing at least two types of fascia panel, a first of the at least two types of fascia panel having a first decorative appearance, and a second of the at least two types of fascia panel having a second decorative appearance different from the first decorative appearance; and selecting one of the at least two types of fascia panel for attachment to the outer attachment surface of the substructure member. 